Moisture management sock

ABSTRACT

A moisture management sock is disclosed. One example embodiment includes one or more channels underneath the sock to transfer moisture from one or both of the heel or toes on the bottom of the sock. Some embodiments transfer moisture from the bottom of the sock around the arch to the top of the foot. Some embodiments include elements for drying the heel and/or toe and transferring it through the arch around the top of the foot.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.61/678,031, filed Jul. 31, 2012.

BACKGROUND

1. Field of the Invention

This disclosure relates generally to all types of socks, and moreparticularly to a sock that aids in moisture distribution, wicking, andevaporation using hydrophilic and hydrophobic yarns which work torespectively absorb and transfer moisture.

2. Prior Art

The moisture that occurs or develops in the foot area may beuncomfortable and can increase odds for blisters or other foot ailments.Socks made from significant amounts of hydrophobic (i.e. non-absorbent)yarn, such as synthetic resinous material (petroleum based), can becomeuncomfortably wet underfoot due to impeded air flow and heat retentivecharacteristics of the yarn. However, socks made predominantly fromhydrophilic yarn may soak moisture from a foot but then hold themoisture in the sock. There is need for an improved sock in whichmoisture collection and disposition are better managed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a side view of one embodiment of a moisture managementsock.

FIG. 2 shows a top view of the embodiment of a moisture management sockin FIG. 1.

FIG. 3 shows a bottom view of the embodiment of a moisture managementsock in FIG. 1.

FIG. 4 shows a side view of an embodiment of a moisture management sock.

FIG. 5 shows a top view of the embodiment of a moisture management sockin FIG. 4.

FIG. 6 shows a bottom view of one embodiment of a moisture managementsock.

FIG. 7 shows a bottom view of one embodiment of a moisture managementsock.

FIG. 8 shows a bottom view of one embodiment of a moisture managementsock.

FIG. 9 shows a bottom view of one embodiment of a moisture managementsock.

FIG. 10 shows an enlarged view of the stitch loop construction in aboundary area between hydrophilic and hydrophobic yarns in a moisturemanagement sock.

FIG. 11A is a schematic diagram illustrating a square-wave pattern ofthe moisture transfer interface of the interlocking finger portions.

FIG. 11B is a schematic diagram of the interlocking finger portions ofFIG. 11A, in an assembled view.

FIG. 12A is a schematic diagram of the first and second knit portions ofthe sock assembly, in a disassembled view, illustrating an alternativeembodiment sawtooth pattern of the moisture transfer interface of theinterlocking finger portions.

FIG. 12B is a schematic diagram of the sawtooth pattern interlockingfinger portions of FIG. 12A, in an assembled view.

FIG. 13A is a schematic diagram illustrating a square-wave pattern ofthe interlocking finger portions having sawtooth pattern edges.

FIG. 13B is a schematic diagram of the sawtooth edge interlocking fingerportions of FIG. 13A, in an assembled view.

DETAILED DESCRIPTION

This disclosure relates to multiple embodiments of a moisture managementsock with various combinations of yarn to absorb moisture from wet partsof a foot and transfer the moisture to drier parts of the sock. Oneexample embodiment includes one or more channels underneath the sock totransfer moisture from one or both of the heel or toes on the bottom ofthe sock. Some embodiments transfer moisture from the bottom of the sockaround the arch to the top of the foot. Some embodiments includeelements for drying the heel and/or toe and transferring it through thearch around the top of the foot. These and other embodiments aredescribed in more detail in the following description.

FIGS. 1-3 show one embodiment of a moisture management sock 100 withzones of hydrophobic yarn 10, 12 and 18 and zones of hydrophilic yarn13, 15, 17 and 19. Sock 100 includes interposing channels or fingers ofhydrophilic and hydrophobic yarns in regions 21, 22 and 23 asillustrated in the figure between the boundary of heel and instep andtoe and instep. In this embodiment, band 17 of hydrophilic yarn wrapsaround the front portion of the foot while fingers or channels 19 extendfrom the arch of the foot around the instep and into the zone ofhydrophobic yarn on the top of the instep 12. Other embodiments may havea different arrangement of bands or channels of hydrophobic andhydrophilic yarn. Some embodiments include features from one or moresocks disclosed in U.S. Pat. Nos. 4,898,007, 5,511,323, 6,082,146,6,341,505 and 7,552,603, the contents of which are incorporated hereinfor all purposes.

Referring now to FIG. 3, the sole of sock 100 includes a heel portion15, one or more channels 19, a band 17, and toe portion 13 comprisinghydrophilic yarn and band 18 and zone 14 comprising hydrophobic yarn. Inother embodiments the zones of hydrophilic yarn may primarily comprisehydrophilic yarn but have blends of yarn and the zones of hydrophobicyarn may primarily comprise hydrophobic yarn but have blends of yarn. Insome embodiments the hydrophilic and hydrophobic yarn may not be theprimary composition of their respective zones but may have enoughdifferential hydrophobic and hydrophilic yarn composition to stilloperate to wick moisture from wet areas of the sock to evaporative areasof the sock, as shown in the example in FIG. 10.

In further discussion of sock 100 as illustrated in FIG. 3, interposingchannels or fingers of hydrophilic and hydrophobic yarns in regions 21and 23 operate as a conduit for moisture in toe and heel regions 13 and15 to the wicking hydrophobic sections 14 and 18 (and ultimately 12and/or 10) of sock 100. Further aiding in the transfer of moisture fromhydrophilic sections 13 and 15 are channel(s) 19 and band 17. Thesehydrophilic sections operate to draw moisture through hydrophobicsections 14 and 18 from heel 15 and toe 13 regions by capillary action.Some embodiments may utilize sections 21 and/or 23 without use ofchannel(s) 19 or bands 17. Further, some embodiments may utilize adifferent combination of bands or channels, including only channels orbands or even a singular channel or band. In yet another embodiment, anycombination of one or more channels or bands may be used exclusive tothe interposed regions 21 and 23, however, a combination of interposedregions 21 and 23 and one or more channels or bands may wick moremoisture from a wet sole of sock 100.

In one embodiment, the first knit portion 13 includes a plurality ofelongated channels or finger portions in zone 23 that are spaced-apartfrom one another and defined by a respective edge. The channel or fingerportions in zone 23 (and zones 21 and 22) increase the boundary lengthbetween the hydrophilic yarns and hydrophobic yarns as well as operateas channels to wick or pump moisture from the wetter hydrophilic yarnzones to the drier hydrophobic yarn zones. By increasing the surfacecontact at the transfer interface, moisture flow is promoted across theinterface.

The moisture management sock 100 of the present embodiment may includethree primary yarn zones: the cup-shaped, and channeled first knitportion 13 at the toe of the sock; a smaller cup-shaped third knitportion 15 at the heel of the sock; and a generally tubular andchanneled second knit portion 12 at instep and over the instep. However,other embodiments may have different shaped sections for these sameprimary zones or may have a different number or arrangement of primaryyarn zones.

In the present embodiment, the channeled first knit portion 13 ispredominately comprised of hydrophilic yarn (i.e. characterized astending to absorb moisture from the toe area of the wearer's foot),particularly at the underside of the wearer's toes which the socksupports and cushions. In this way, at the top and bottom regions of thefirst knit portion 13 the plurality of alternating channel or fingerportions are disposed which extend generally rearward in a directiontoward instep portion 12.

Further, the heel portion 15 of sock 100, as shown in FIGS. 1 and 3, maypredominately comprise hydrophilic yarn (i.e. characterized as tendingto absorb moisture from the heel area of the wearer's foot). This isparticularly true at the underside portion of the wearer's heel whichthe sock supports and cushions. Heel portion 15 also distributesmoisture to the instep 12 using channels or fingers of interspersedhydrophilic and hydrophobic yarn as shown in zone 21 in FIGS. 1 and 3.

The channeled portions 21, 22 and 23 at the instep of the sock arelocated between the toe portion 13, the heel portion 15 and the instep12 (top, bottom and/or sides). Moisture absorbed from heel and toeregions is transferred to the instep 12, and on to the exterior thereofas by wicking and evaporation. This interlocking channeled designsignificantly accelerates and improves the amount of moisture drawn fromthe toe and heel portions, through the arch of the foot, and to the topof the foot and the vertical tube 10 of the sock.

In some embodiments, interposed channel regions 21, 22 and 23 work incombination to wick moisture from heel and toe regions of socks 100 and200 to hydrophobic yarns in either instep 12 or leg 10 and therefore bycapillary action dry the socks 100 and 200. In yet another embodiment,interposed channel regions 21, 22 and 23 may be used with one or morechannels 19, 19 b and/or bands 17. In some embodiments, the horizontaland vertical yarn placement in the arch of the sock improves themovement of moisture to the top of the foot and up the leg.

Further, some embodiments may be tailored to specific uses by adjustingthe design or number of horizontal zones placed in the instep of thesock 100. In this way, the capillary action can be increased ordecreased according to the wearers need. More strenuous activity mayutilize more hydrophobic bands (for example: Hiking, Skiing andrunning), while dress socks and casual wear may utilize fewerhydrophobic bands or different geometries.

FIGS. 4 and 5 show side and top views of an embodiment of a moisturemanagement sock 200. Sock 200 comprises a similar design to moisturemanagement sock 100 but includes additional channels 19 b as shown onthe lateral top of the instep 12 as illustrated. Isolated channels ofhydrophilic material as depicted in 19 b can create a conduit to drawmoisture by capillary action from the sole of the foot, from channel 19or from the heel 15 and toe 13 regions and to then become a reservoir ofmoisture to be wicked by capillary action through the top of instep 12or up the leg 10 of sock 200.

FIG. 6-9 show bottom views of additional embodiments of a moisturemanagement sock. The embodiment in FIG. 6 includes multi-zone channelsthat include both hydrophilic and hydrophobic regions of interposedchannels (such as in interposed regions 21, 22 and 23). These multi-zonechannels can more quickly absorb moisture from the heel and toe regionsof a sock and therefore increase the amount transferred to thehydrophobic center portion of the sock to wick away from wet sock areas.

The embodiment in FIG. 7 includes channels and a band on the foot archas well as semi-circular homophobic regions placed within heel and toeregions yet still connected to homophobic material through the arch ofthe foot. The embodiment in FIG. 7 increases boundary surface areabetween hydrophilic and hydrophobic yarns while having a large wickingchannel connecting heel and toe portions with the hydrophobic yarns inthe arch. FIG. 8 depicts a similar design as the semi-circularembodiment in FIG. 7 but utilizes tear drop shapes interposed into theheel and toe as opposed to semi-circular regions. FIG. 9 illustrates anembodiment with arrow shaped channels into the heel and toe regions. Insome embodiments, the channels can be rounded at the edges for betterdesign aesthetics and ease of manufacturing. The channels can alsochange to better incorporate with the end use of the product. Forexample, if the sock is to be used in primarily dress applications andthe aesthetic of visible channels above the shoe is deemed undesirable,the channeling and zones may be modified accordingly yet still retaintheir function.

FIG. 10 shows an enlarged view of the stitch loop construction in aboundary area between hydrophilic and hydrophobic yarns in a moisturemanagement sock. As shown in the portion of knit fabric of FIG. 10,needle wales W-3, W-4 and W-5 are located in the upper half of the footand needle wales W-1 and W-2 are located in the lower half or sole ofthe foot. The portion of the knit fabric in courses C-1, C-2 and C-3 islocated in the instep portion of second knit portion 30 and to the leftof the edge 16 while the courses C-4 and C-5 are located in the ballportion of the toe first knit portion 31. In the pictured embodiment,the entire foot is knit throughout of a hydrophobic binder or body yarnB while additional hydrophilic yarn C (striped in FIG. 10) is knit inplated relationship with the body yarn B in the first and third knitportions 13, 15 (toe and heel portions of FIG. 1), and additionalhydrophobic yarn N (plain in FIG. 10) is knit in plated relationshipwith the body yarn B in the second knit portion 12 (instep and soleportion). As shown, terry loops T are formed of the yarns C and N in thesinker wales between the needle wales W-1, W-2 and W-2, W-3.

In some embodiments, the hydrophobic body yarn B forms a base or groundfabric and is much smaller than the additional hydrophobic yarn N andthe additional hydrophilic yarn C. For example, in an athletic typesock, it may be preferred that the body yarn B be a textured stretchnylon of two-ply, 100 denier (total of 200 denier), the additionalhydrophobic yarn N be an acrylic, such as Creslan, of two ends, 24single count (equivalent to 443 denier), and the additional hydrophilicyarn C be a 12 single count cotton yarn (equivalent to 443 denier). Inthis particular example, the amount of the hydrophobic body yarn B issubstantially one-half the amount of the hydrophilic yarns C in thefirst and third knit portions 13, 15 and the hydrophobic yarn N in thesecond knit portion 12.

Thus, the first and third knit portions 13, 15 (heel and toe portions)are knit predominately of hydrophilic yarn while the second knit portion12 (instep and sole portion) is knit entirely of hydrophobic yarn.Opposite ends of the second knit portion 12 are joined edgewise orcoursewise to the adjacent ends of the corresponding first and thirdknit portions 13, 15 so that moisture absorbed from the wearer's foot bythe predominately hydrophilic yarn C in the first and third knitportions 13, 15 (toe and heel portions) is transferred by wicking actioninto the predominately hydrophobic yarn N in the second knit portion 12(instep portion) to be evaporated therefrom, as indicated by the arrowsin FIG. 10, showing the path of travel of the moisture from the firstknit portion (toe) 13 to the second knit portion (instep) 12. As shownin FIG. 1, the toe portion 13 also includes an adjacent portion of thefoot of the sock which is adapted to engage and underlie the ball of thewearer's foot. This ball portion is also knit predominately of thehydrophilic yarn C.

While the hydrophobic body yarn B is knit throughout the sock, for thepurpose of providing sufficient stretch to the sock to fit a range offoot sizes, it is to be understood that the sock can be knit without abody yarn. In this instance, the first knit portion (toe) 13 and thethird knit portion (heel) 15 will be knit entirely of hydrophilic yarn Cand the second knit portion (instep) 12 will be knit entirely of thehydrophobic yarn N. Thus, when the first knit portion (toe) 13 and thethird knit portion (heel) 15 are described as being knit predominatelyof the hydrophilic yarn, this is intended to also mean that these zonescan be knit entirely of the hydrophilic yarn.

Example hydrophobic yarns include alpaca wool, merino wool, cotton, andother natural yarns or suitable variants. These natural fibers arehydrophilic and therefore absorb moisture. However, moisture evaporatesrelatively slowly from this type of fiber due to its tendency to absorbthe moisture. When the natural fibers are enclosed in a warmenvironment, such as a shoe or boot, and active or at rest, the footcontinuously produces moisture. In this way the natural fibers absorbthe moisture and create wet socks which may cause a variety of unwantedailments. However, socks made with hydrophobic yarns do not easilyabsorb and retain the moisture and because of that, can leave the footwet and uncomfortable. Additionally, synthetic fibers often operate asthermal insulators, compounding the problem with increased footmoisture. Embodiments disclosed herein use hydrophilic yarns in areaswhere moisture is produced and hydrophobic yarns to draw moisture out ofthe hydrophilic areas. In this way, capillary action pulls the moisturetoward the drier hydrophobic fibers where it can more readily evaporate.

FIGS. 11A-B illustrate a first knit portion 11 and second knit portion13 featuring square-wave style channels. FIG. 11A depicts an enlargedtop plan view of the first knit portion 11 and second knit portion 13,in a disassembled state, that more clearly illustrate respectiveinterface edges 11 d and 13 d. FIG. 11B depicts first knit portion 11and second knit portion 13 in an assembled state so as to more clearlyillustrate resulting contact interface 16.

It will be appreciated, however, that other finger or channel portionsizes and shapes may be incorporated as long as the surface area of themoisture transfer interface significantly increased, thus promotingenhanced moisture transfer thereacross. By way of example, the fingerportions or channels can be of unequal length, as shown in FIGS. 1 and2. Alternatively, the interfacing edges between the interlocking channelportions may be sawtoothed, which would function to increase theinterface surface area contact even more. FIG. 12A and FIG. 12B, forinstance, illustrate one implementation of such a sawtooth pattern. FIG.12A depicts first knit portion 11 and second knit portion 13 in adisassembled state, while FIG. 12B depicts the interlocking first knitportion 11 and second knit portion 13 in an assembled state.

Alternatively, FIGS. 13A and 13B illustrate yet another moisturetransfer interface having a square wave pattern with sawtooth patternedges. FIG. 13A depicts the first knit portion 11 and the second knitportion 13 in the disassembled state, while FIG. 13B represents theinterlocking knit portions in an assembled state.

It will further be understood that the configurations and/or approachesdescribed herein are exemplary in nature, and that these specificembodiments or examples are not to be considered in a limiting sense,because numerous variations are possible. The specific routines ormethods described herein may represent one or more of any number ofprocessing strategies. As such, various acts illustrated may beperformed in the sequence illustrated, in other sequences, in parallel,or in some cases omitted. Likewise, the order of any of theabove-described processes is not necessarily required to achieve thefeatures and/or results of the embodiments described herein, but isprovided for ease of illustration and description.

The subject matter of the present disclosure includes all novel andnonobvious combinations and subcombinations of the various processes,systems and configurations, and other features, functions, acts, and/orproperties disclosed herein, as well as any and all equivalents thereof.

1. A moisture management sock comprising: a first knit portion havinghydrophobic yarn in relation to a second knit portion, the first knitportion substantially wrapping the instep portion of the sock, the firstknit portion including a plurality of elongated finger portionsspaced-apart from one another, said elongated finger portions defined bya respective edge; and a second knit portion having hydrophilic yarn inrelation to the first knit portion, the second knit portion disposedwithin the first knit portion and substantially on the bottom of theinstep portion of the sock, the second knit portion including aplurality of elongated finger portions defined by a respective edge, andsized and dimensioned to intermesh with the respective elongated fingerportions of the first knit portion such that an improved moisturetransfer interface is formed by the hydrophilic yarn absorbing moisturefrom a foot and the hydrophobic yarn transferring the moisture from thesecond knit portion.